Wood filler composition

ABSTRACT

THE PRESENT INVENTION IS CONCERNED WITH A PLASTIC FILLER COMPOSITION FOR FIBROUS OR WOOD PRODUCTS FOR USE IN THE BUILDING MATERIALS AND CONSTRUCTION INDUSTRIES, PARTICULARLY FOR USE WHEN FACE NAILING WOODEN ELEMENTS SUCH AS PLYWOOD PANELS AND BOARDS WHEREIN THE NAILS ARE COUNTERSUNK. THE FILLER IS COMPOSED OF TALL-OIL FATTY ACID ESTER, WAXES, POLYETHYLENE, PIGMENT, TALC, AND OPTIONALLY, AN ANTIOXIDANT.

April 6, 1971 T. G. PARKER 3,574,155

WOOD FILLER COMPOSITION Filed June 17, 1968 IN VE NTOR THOMAS G. PARKER B WPW/W ATTORNEY.

United States Patent 3,574,155 WOOD FILLER COMPOSITION Thomas G. Parker, Fisher Lake, Three Rivers, Mich., assignor to US. Plywood-Champion Papers Inc., New York, NY.

Filed June 17, 1968, Ser. No. 737,710 Int. Cl. C081? 45/52 US. Cl. 260-23 13 Claims ABSTRACT OF THE DISCLOSURE The present invention is concerned with a plastic filler composition for fibrous or wood products used in the building and construction industries, particularly for use when face nailing wooden elements, such as plywood panels and boards, wherein the nails are countersunk. The unique plastic composition of the present invention is a very eifective and attractive material for concealing nail cavities and other indentations, such as scratches and the like.

It is known in the building and construction industry to face nail wooden structural elements, such as plywood panels, moldings, wainscotting, and lumber to supporting studs, rafters, and the like. Thus, when bonding solid or laminated panels to supporting structural elements in order to secure a uniform, aesthetic, pleasing surface, it has been the custom to face nail these panels, countersink the nails and then fill the cavities with putty or equivalent materials which have been colored so as to approximate as closely as possible the color of the installed panel.

It is very difiicult to prepare a filling composition having the desired physical properties, such as consistency and the proper amount of solvent, with the result that many of these compositions, upon drying, shrink away from the surrounding edge leaving an observable crack between the added mixture and the surrounding board. In certain instances, this shrinkage is of such a magnitude that some, or all, of the filler insert will fall out revealing an undesirable looking cavity and at times the countersunk nail.

The present invention is concerned with a solid plastic composition of such a consistency that it may be worked back and forth over the cavity in such a manner that the cavity or indentation is gradually completely filled with the plastic material. The color of the composition is the precise color and tone as the panel with its final finished color. By the use of this technique it is impossible, except for a minute examination, to detect where the nail has been countersunk.

The various ingredients which comprise the composition are listed in the following Table I:

TABLE I Desirable specific Preferred compo Range range sition Ester of tall 011 fatty acids(1) 23-32 26-29 27. 5 OXldlZed Flscher-Tropsch wax (2) 2-8 4-6 5. 0 P01 yethy1ene( T 3-12 5-10 7. 5 Oxidized microcrystallme wax(4) .l- 15-25 18-22 20. 0 Parafiin wax(5) 15-25 18-22 20. 0 Soft microcrystalhne wax (6) 14-18 16. 0 P gment(7) 2-4. 5 3. 0 Mlcrofine talc 1-7. 0 1. 0

Total 1 100. 0

l Antioxidant may be added.

Norm-Number references in parentheses are referring to tex below.

(1) Aristo International Chemical Company, 600 B. Davidson Road, Detroit 12, Mich.:

(a) Viscosity=Z-ZS (Gardner) (b) Color=12 maximum (Gardner) (0) Solids=l00% (e) Description of oil-Glycerol ester of tall oil fatty acids with a small amount of acid anhydride. This ester contains free fatty acids which are mixtures of oleic, linoleic, and palmitic acids; also contains free mono, di, +triglycerides. Molecular weight range Forester is approximately 1200-1800; molecular weight for triglyceride is approximately 940; molecular weight for palmitic acid is approximately 256; molecular Weight for oleic and linoleic are both approximately 282.

(2) Petrolite Company, Bareco Wax Div., Box 390, Kilgore, Tex., Petrolite C-400:

(a) Melt pt.=215-225 F. (ASTM D-127-49) (b) Penetration-=3 (ASTM D-132l) (c) Color=cream white (ASTM D-1500) (d) Acid No.=10-15 (e) Saponification No.=2030 (3) Epolene N-14 Eastman Chemical Products, Inc., Kingsport, Tenn.:

(a) Softening pt.=approx. 223 F. (ASTM D-36- (b) Penetration=2 maximum (ASTM D-132l) (c) Color=2 (Gardner) (d) Molecular weight=approximately 2500 (2000- (e) Brookfield viscosity at 250 F.=2200-2700 cp.

(f) Acid No.= 0.1

(g) Saponification No.= 0.1

(h) Coeflicient of linear thermal expansion:

10.5 10- in./in./ F.

(i) Dielectric constant=2.36

(j) Dissipation factor=3.03.5 X 10- (k) Volume resistivity at 23 C.'=1 10 (4) Petronauba W Petrolite Company, Bareco Wax Div., Box 390, Kilgore, Tex.:

(a) Melt pt.=180 F. minimum (ASTM D-l27-49) (175 F.l F.)

(b) Penetration=8 (ASTM D-l32l) (c,) Color=cream white (ASTM D-l500) (e) Saponification No.=4555 The oxidized wax makes it easier to emulsify. This particular wax also imparts certain desired properties to the composition such as medium hardness, melting point and pigment dispersion.

(5) Parvan 3050, Humble Oil and Refining Co., Oak Brook, 111.:

(a) Melt pt.=131 F. (ASTM D87) (l25137 F.) (b) Penetration=15 (ASTM D1321) at 77 F.

(12-18) Color=+30 (ASTM D-156) (d) Oil content=0.2% (ASTM D72l) (e) Refractive index at 67 C.: 1.4330 (ASTM D- 1218) (f) Flash point C.O.C. F.=41 (ASTM D92) (g) Kinematic viscosity at 210 F.=3.7 (ASTM D- 445) (h) Wt./gal. at 1150 F.=6.47 (ASTM D-287) (i) Tensile strength at 730 F.=400 p.s.i. (ASTM D-1320) (j) Gradient blocking pt.=96 F. (ASTM D-1465) (6) Cryofiex Amber, Petrolite Company, Bareco Wax Div., Box 390, Kilgore, Tex.:

(a) Melt pt.=150-165 F. (ASTM D938) (b) Congealing pt.=140155 F. (ASTM D-127) -(c) Penetration=50-65 (ASTM D-1321) (d) Color=l.5 maximum (ASTM Dl500) (e) Acid No. and Saponification No.=both Nil Alternate to above.(For harder stick and easier cleanup) Be Square, Petrolite Company, Bareco Wax Div., Box 390, Kilgore, Tex.:

(a) Melt pt.=170l75 F. (ASTM Dl27.49) (b) Penetration at 77 F.=20 (ASTM Dl 321) (c) Acid No.=Nil

(d) Saponification No.==Nil (e) Color=l.5 max. (ASTM DlSOO) (7) Satisfactory pigments which may be used as such or in mixtures may comprise chrome yellow, titanium yellow, ocher, burnt umber, burnt sienna, and the like. Other pigments which may be used are titanium white--TiO raw sienna, ra-w umber, chrome oxide green, iron oxide black, lamp black, phthalocyanine green, phthalocyanine red, and phthalocyanine blue.

While the foregoing materials are critical for the best results, under certain conditions other alternate ingredients may be used as, for example:

- Amorphous polypropylene (Eastobond M-3), Eastman Chemical Products, Inc. This may replace the N-14 polyethylene (3) if necessary in order to increase the viscosity of the melt.

(a) Softening pt.==208 F. (ASTM D-3626) (b) Penetration 4.0 (ASTM Dl321) (c) Brookfield viscosity cps.=6300 at 275 F (d) Color=2.5 Gardner Scale (e) Range=510% in formula (f) Molecular wt.=approx. 7,000-8,000

Ethylene ethyl acrylate copolymer (Zetafax 1175); This may also be used as replacement for polyethylene, Dow Chemical Co., Midland, Mich. (3) in order to increase viscosity of the melt.

(a) Color=white (b) Hardness=27 (Shore D) (c) 'Vicat softening pt.=95 F. (d) Range=510% in formula (e) Molecular wt.=19,00021,000

P-53 Parafiin Wax, Kalamazoo Parafiine Co., 1809 Reed St., Kalamazoo, Mich. to replace paraflin wax (5) (a) Melting point=149.5 F. (ASTM D87) (b) Odortaste=Nil (c) Color=+30 (ASTM D-156) (d) Oil content= 0.007% (ASTM D72l) (e) Refractive index=1.4305 (ASTM D-1218) (f) Viscosity kinematic at 180 F.:7.48 (ASTM D- 4 (g) Tensile strength at 73 F.=365 (ASTM D- 1320) (h) Gradient blocking pt.= F. (ASTM D- 1465) (i) Penetration at 77 F.=14 (ASTM D1321) An antioxidant may also be included regardless of any change in formula. Two satisfactory antioxidants are:

(A) Butylated hydroxyanisole (Tenox BHA) Eastman Chemical Products, Inc.:

(a) Physical appearance=white waxy tablets (b) Odor=slight (c) Melting range=54-58 C.

(d) Molecular weight= (B) Butylated hydroxytoluene (Tenex BHT) Eastman Chemical Products, Inc.: (a) Physical appearance=white crystals (b) Odor=very slight (c) Melting range=69-70 C. (d) Molecular wt.=220

The amount of antioxidant used is in the range of about 0.1 to 0.5% such as about 0.25%. The composition may be extruded or otherwise formed in any suitable geometric shape which may be conveniently and firmly held in the hand of the user.

A very desirable composition for the wedge has the following physical properties:

(a) Density=about 1 g./ml.Range 0.5 to 1.5

g./ml.

(b) Melt p:t.=range about 194202 F. (ASTM D- (c) Penetration at 77 F.=21 100 g./5 sec. at 77 F.

(ASTM D-132l) (Range 18 to 24) Referring to the drawing:

Numeral 1 is the sharp pointed edge of the wedge, while 2 indicates the blunt rounded edge formed by radius R with its center at the thickest portion of the wedge.

It has been found that the best configuration is wedgeshaped or tear drop-shaped having one extended and pointed edge and one rounded arc-like edge. Cone-shaped points, as in a pencil, wear ofi quickly but in the form shown in the drawing, the sharp edge 1 will remain until the plastic wedge is too small to be held. Thus it is preferred that the geometric configuration be in the shape of an elongated wedge or elongated tear drop.

The knife edge 1 can be used for nail holes, grooved edge separations between adjacent panels, etc., while the rounded, blunt edge 2 can be best used for large, shallow gouges, scratches and the like. The wedge is preferably from 3 inches to 12 inches in length, with an optimum length of about 4 inches and a blunt edge having a radius of about /2 inch to one inch.

The advantages secured by the geometrical configuration of the present wedge are that it will not roll when it is dropped or placed on an inclined rest. Also the knife edge is more suitable for filling the V-grooves in the finished paneling. Furthermore, by switching edges, either small or large holes can be conveniently filled. Since two wedges will nest, they are more convenient to package and ship.

The composition of the present invention is also very desirable since it has greater tensile strength and flexibility, and has much less tendency to break during use or when dropped than any heretofore known filling compositions. It has better workability at low and high temperatures, and is usable and workable over a wide temperature range. The wedge has less distortion and better storage life at high temperatures and has less tendency to dry out and to change consistency and become hard than previously known compositions.

The composition of the wedge has greater cohesive strength and will not shrink and thus will not fall from the filled cavity. The composition will not mar the surface of the finished panel, nor stick on the surface surrounding the filled hole. Hence the excess may be readily removed without damage.

The composition gradually fills the hole by intrusion and not by bridging over or flaking thereby securing a completely filled hole not having any voids in the body of the filler. Thus, the wedge of the present invention may be readily used for filling in nail holes and other cavities thereby to preserve the beautiful appearance of the installed panel throughout its entire surface area. The wedge of the present invention will provide a gloss comparable to the gloss of the panel finish, and will also provide a nonshrinking composition. The wedge can be used in either interior or exterior structures and is readily available in all colors and shades depending upon the pigment used.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A homogeneous solid wood filler composition which consists essentially of about 23 to 32 wt. percent of esters of tall oil fatty acids, about 3 to 12 wt. percent of polyethylene having a molecular weight in the range from about 2000 to 3000 and a viscosity in the range about 2200 to 2700 cp. at 250 F., and about 74 to 56 wt. percent of a mixture of paraflin waxes and rnicrocrystalline waxes.

2. Wood filler composition as defined by claim 3 wherein the density of the same is in the range from about 0.5 to 1.5 g./ml., wherein the melting point is in the range from about 194 to 202 F. and wherein the penetration is in the range from about 17 to 24 (100 g./ 5 sec. at 77 F.).

3. A homogeneous solid wood filler composition having a density in the range from about 0.5 to 1.5 g./ml., a melting point in the range from about 194 to 202 F., and consists essentially of about 2 6 to 29 wt. percent of esters of tall oil fatty acids, said esters having a viscosity of ZZ5 on the Gardner scale; about 5-10 wt. percent of polyethylene having a molecular weight in the range from about 2000 to 3000 and a viscosity in the range from 2200 to 2700 cp. at 250 F.; about 18 to 22% by weight of an oxidized microcrystalline wax having a melting point in the range from about 175 F. to 185 R, an acid number in the range from about 22 to 30 and a saponification number in the range from about 45 to 5 5 about 18 to 22% by weight of a paraffin wax having a melting point in the range from about 125 F. to 137 F., containing about 0.2% of oil and having a penetration in the range from about 12 to 1-8 at 77 F.; about 14 to 18% by weight of a soft microcrystalline wax having a melting point in the range from about 150 to 165 F. and a penetration in the range from about 50 to 65; and containing minor amounts of pigment and talc.

4. Wood filler composition as defined by claim 3 wherein minor amounts of talc and pigment are present.

5. Wood filler composition as defined by claim 3 wherein said mixture comprises about 12 to 20 wt. percent of soft microcrystalline wax, about 15 to 25 wt. percent of oxidized microcrystalline wax, and about 15 to 25 wt. percent of parafiin wax having a melting point in the range from about 125 F. to 137 F.

6. A composition as set forth in claim 3 consisting of approximately 27.5 wt. percent of esters of tall oil fatty acids, approximately 7.5 wt. percent of polyethylene, approximately 61 wt. percent of said waxes, and approximately 4 wt. percent of pigment and tale.

7. A composition as set forth in claim 6 wherein the approximate 61 wt. percent of said waxes consists of approximately 5 wt. percent of oxidized Fischer-Tropsch wax, approximately wt. percent of oxidized microcrystalline wax, approximately 20 wt. percent of paraflin wax, and approximately 16 wt. percent of soft microcrystalline wax, and the approximate 4 wt. percent of pigment and talc is approximately 3 wt. percent of pigment and 1 wt. percent of microfine talc.

8. A composition as set forth in claim 7 wherein approximately 0.1 to 0.5% of antioxidant is added.

9. A composition as set forth in claim 8 wherein the composition has the following physical properties:

(a) Density=about 1 g./ml.Range 0.5 to 1.5 g./ml.

(b) Melt pt.=range about 194-202 F. (ASTM D-127-49) (c) Penetration at 77 F.=21 g./5 sec. at 770 F.

(ASTM D-1321) (Range 18 to 24).

10. A composition as set forth in claim 3 wherein the composition has the following physical properties.

(a) Density=about 1 g./ml.Range 0.5 to 1.5 g./ml.

(b) Melt pt.=range about 194-202 F. (ASTM D127-49) (c) Penetration at 770 F.=21 100 g./5 sec. at 77 F.

(ASTM D-1321) (Range 18 to 24).

11. A homogeneous solid wood filler composition having a density in the range from about 0.5 to 1.5 g./ml. a melting point in the range from about 194 to 202 F., and comprising about 26 to 29 wt. percent of esters of tall oil fatty acids, said esters having a viscosity of Z-ZS on the Gardner scale; about 5-10 wt. percent of polyethylene having a molecular weight in the range from about 2000 to 3000 and a viscosity in the range from 2200 to 2700 cp. at 250 F.; about 18 to 22% by weight of an oxidized microcrystalline wax having a melting point in the range from about 175 F. to 185 R, an acid number in the range from about 22 to 30' and a saponification number in the range from about 45 to 55; about 18 to 22% by weight of a paraffn wax having a melting point in the range from about F. to 137 F., containing about 0.2% of oil and having a penetration in the range from about 12 to 18 at 77 F.; about 14 to 18% by weight of a soft microcrystalline wax having a melting point in the range from about to F. and a penetration in the range from about 50 to 65; and containing minor amounts of pigment and talc.

12. A shaped article consisting essentially of the composition set forth in claim 1.

13. A shaped article consisting essentially of the composition set forth in claim 3.

References Cited UNITED STATES PATENTS 995,780 6/ 1911 Fuerth. 2,728,735 12/1955 Anderson 26028.5 3,139,412 6/1964 Sterling 2-6023 FOREIGN PATENTS 27,635 2/1964 Japan 260-23UX OTHER REFERENCES Bennett: The Chemical Formulary, vol. XIII, Chemical Publishing Co., New York (1967), p. 173. Call No. TT P151 B 35.

Soderberg: Finishing Materials and Methods, McKnight & McKnight, Bloomington (Illinois) (1959), pp. 133-135. Call No. TI385575.

DONALD E. CZAI A, Primary Examiner H. S. COCKERAM, Assistant Examiner US. Cl. X.R. 

